Abstract: A composite thermal spray powder, for producing abradable coatings, is substantially in the form of clad particles each of which has a core particle of boron nitride and subparticles of aluminum-silicon alloy. The subparticles are bonded to the core particle with an polymeric binder.

Abstract: A powder injection apparatus for a plasma spray gun includes a block having channelling therein for liquid coolant. A powder port extends through the block in proximity to the channelling so as to be cooled by coolant flowing therein. The port has a powder inlet receptive of spray powder in a carrier gas, and has a powder outlet end formed as a tubular protrusion extending from the block. A pair of extensions extend from the block proximate the protrusion on diametrically opposite sides thereof. Each extension has at least one orifice therein disposed so as to direct gas onto the protrusion. A pair of additional gas exit openings direct gas to the face of the gun.

Abstract: A tenacious wear resistant coating is applied with a high velocity oxygen-fuel thermal spray gun using a composite powder of aluminum and an iron base metal. The metal may be iron-chromium, iron-molybdenum, cast iron or a combination. A particular combination is a blend of a first powder and a second powder, the first powder consisting of a composite of aluminum subparticles and iron-molybdenum alloy subparticles, and the second powder consisting of a composite of aluminum subparticles and cast iron subparticles. An internal combustion engine block has such a coating applied to the cylinder walls.

Abstract: A superconductive oxide powder is produced by a method comprising spray drying a slip to form agglomerates, feeding the agglomerates sequentially through a first and a second oxygen supported combustion flame for fusing the fine particles in the agglomerates to form an intermediate powder, annealing the intermediate powder in an oxygen-containing environment such as to produce a friable mass, and crushing the mass to form the superconductive oxide powder. For example, a precursor compound in the slip is barrium carbonate, the other precursor constituents are yttrium oxide and copper oxide, and the yttrium, barium and copper in atomic proportions in the precursor constituents are 1:2:3+Y where Y denotes a copper surplus having a value of up to about 1.5. In the final powder the proportions are 1:2:3+Z where Z is between about 0.2 and 1.0.

Abstract: A thermal spray powder is formed of granules of a silicon aluminum alloy each having bonded thereto discrete particles of a neoalkoxy zirconate type of organo-zirconate. A modified polyester powder may be blended with the mineral granules, in which case the polymeric granules also should have the zirconate bonded thereto. The powder is made by forming a slurry of alloy and zirconate starting powders with an organic binder, and drying the slurry to form the powder.

Abstract: Two constituent powders of a powder blend for thermal spraying are in the form of composite particles containing subparticles of nickel alloy and benoite for clearance control coatings. The composite particles are formed by spray drying. In one embodiment the volume percentage of metal in one constituent powder is at least 25% greater than in the other powder. In another embodiment the difference is about 10% by volume, and the alloy rich constituent has alloy subparticles sufficiently large to act as core particles to which the finer subparticles of bentonite are bonded.

Abstract: A rotor blade is for a gas turbine engine having a plurality of rotor blades and a substantially coaxial shroud encompassing the tips of the blades. A ceramic layer is bonded to the blade tip, the ceramic layer consisting of a combination of aluminum oxide and zirconium oxide or at least partially stabilized zirconium oxide. The ceramic layer is formed as a plasma sprayed coating or a high velocity oxy-fuel sprayed coating.

Abstract: A composite thermal spray powder for abradable coatings is formed as homogeneously agglomerated particles. Each agglomerated particle consists of pluralities of subparticles of boron nitride and subparticles of aluminum or aluminum alloy bonded with an organic binder.

Abstract: Manufacture of glass mold plungers utilizes a thermal spray gun having combustion chamber with an open channel for propelling combustion products into the ambient atmosphere at supersonic velocity. The method comprises injecting into the chamber a combustible mixture of combustion gas and oxygen at a pressure in the chamber of at least two atmospheres above ambient atmospheric pressure, feeding into the chamber a powder comprising self-fluxing alloy particles, and combusting the combustible mixture in the chamber means whereby a supersonic spray stream containing the powder is propelled through the open channel. The spray stream is directed toward a glass mold plunger substrate such as to produce a coating thereon which is ground and polished. The coating may be fused prior to grinding.

Abstract: A method for producing a dense and tenacious coating with a thermal spray gun including a nozzle member and a gas cap. The gas cap extends from the nozzle and has an inwardly facing cylindrical wall defining a combustion chamber with an open end and an opposite end bounded by the nozzle. An annular flow of a combustible mixture is injected at a pressure of at least two bar above atmospheric pressure from the nozzle coaxially into the combustion chamber. An annular outer flow of pressurized air is injected from the nozzle adjacent to the cylindrical wall. Powder particles having a heat-stable, non-fusible component and a heat-softenable component, and entrained in a carrier gas, are fed axially from the nozzle into the combustion chamber. An annular inner flow of pressurized air is injected from the nozzle into the combustion chamber coaxially between the combustible mixture and the powder-carrier gas.

Abstract: A thermal spray material has been developed that includes a composite powder comprising chromium carbide or chromium boride and copper or copper alloy in the form of kernels of the chromium carbide or boride clad with the copper or copper alloy. Preferably the thermal spray material includes a self-fluxing alloy composition.

Abstract: A flame spray ceramic powder is provided consisting essentially of about 10 to 50% alumina and the balance essentially zirconia. Preferably, the zirconia is stabilized. A method is disclosed for flame spraying the coating composition onto a metal substrate.

Abstract: Relates to a coating alloy consisting essentially by weight of up to about 0.1% C, about 3% to 30% Mo, up to about 3% Si, up to about 6% W, about 2.5% to 12% Ti, about 10% to 22% Fe, up to about 0.4% V, and the balance essentially nickel.

Abstract: A free-flowing self-bondable flame spray powder derived from an atomized alloy powder is provided in which the particles are characterized by aspherical shapes and have an average particle size within the range of about plus 400 mesh to minus 100 mesh. The aspherically shaped powder is further characterized by a specific surface of about 180 cm.sup.2 /gr and higher and has a composition consisting essentially by weight of up to about 0.1% C, about 3% to 30% Mo, up to about 3% Si, up to about 6% W, about 2.5% to 12% Ti, about 10% to 22% Fe, up to about 0.4% V, and the balance essentially nickel.